In this white paper, we present the innovative commercial GPU-based Computational Fluid Dynamics (CFD) solver Altair ultraFluidX. This work features simulations of the DrivAer model, a generic, publicly available vehicle geometry that was developed by the Chair of Aerodynamics and Fluid Mechanics at the Technical University of Munich and which is widely used for testing and validation purposes.

The DrivAer model features rear end, underbody designs, and underhood flow. This model was then used to perform both wind tunnel tests and numerical simulations of the 40% scale open cooling geometry using perforated aluminum sheets with different opening ratios to mimic different radiator properties. Within, we will compare some of the results from these wind tunnel tests with numerical results obtained with Altair ultraFluidX.

A multi-disciplinary optimization (MDO) approach allows you to explore all design requirements simultaneously and achieve lighter products, faster. Until now, enabling this process on live vehicle programs has been a challenge. Altair's MDO Director is a novel set of software tools that provides a process to rapidly set up, execute, post-process and explore the design of MDO problems.

The script computes and displays an inverse synthetic aperture radar (ISAR) image from backscattered radar cross section (RCS) data over frequency and angle. Windowing functions, resampling and extracting the local maxima positions to file are supported. The script requires a far field RCS request or far field RCS data imported from a file containing far field data (a .ffe file). Data imported from a .ffe file must be added manually to a 3D view.

In an electric machine, the torque is generated by electromagnetic forces which also create some parasitic vibrations of the stator. These vibrations excite the mechanical structure on which the motor is fixed and generate sound. When designing the electric machine, this aspect has to be taken into account from the start since it depends on the harmonic content of the currents that feed the machine, on the shapes of the rotor and stator, and on the interaction of the electric frequencies with the natural mechanical modes of the structure.To simulate this phenomenon, a coupling between electromagnetic calculations and vibration analysis has to be set-up. Some optimization procedure can also be added in order to reduce the noise.In what follows, it is shown how Altair HyperWorks suite; specifically FluxTM, OptiStruct®, HyperMesh® and HyperStudy® products have been successfully used to perform a multi-physics optimization for noise reduction in a fuel pump permanent magnet motor.

Altair's Weld Certification Director (WCD) is a combination of a base software with customer specific additions and integrated services that allows engineers to accelerate the time taken to identify and analyze the performance of weld lines against mechanical requirements.

Altair's Model Verification Director (MVD) allows engineering analysts to validate CAD model data received from the design teams, automatically identifying potential issues that could slow down the pre-processing stage of the simulation life cycle. The MVD is embedded into HyperWorks pre-processing technology, HyperMesh and integrated into the Assembly Browser.

Automotive Noise and Vibration Analysis involves some of the largest and most complex models being used for Finite Element Analysis. Models regularly involve millions of finite elements, with thousands of components and properties, along with the connections between those components.

Correlation between CAE and tests results is very strategic activity. It boosts the confidence in the development of the product. Altair’s Virtual Gauge Director (VGD) is a combination of customized software and services that enable engineers to extract the results at the exact position of the strain gauge as in the test lab, interpolate the results at an identified CAE location, compute results in the local coordinate system of the gauge, and give a correlation index confidence. The Director can also be used to interpolate stress or strain values at any placement in the model.

Altair's Weight Analytics (WA) solution manages the entire Weight and Balance (W&B) process empowering engineering and management teams to control and ensure W&B attributes meet program requirements. Deployed as a common weight management tool across the enterprise, WA enables faster and more accurate decision-making with on-demand access to visualize, analyze and predict W&B at any point in time during the entire Product Lifecycle (PLC).

Analysis of Grounding Performances of a Car Body Using FEM Shell Elements

In the automotive domain, the EMC phenomenon of the current return occurs over a wide frequency band due to the fact that the paths followed by the current are very different between the lowest frequencies (a few Hz) and medium frequencies(hundreds of kHz).

Remanence is what is left when all current is removed, and there is still some flux density left in the iron core. This is often the case with a close path for flux density, especially in U or E shape devices. To get rid of this effect, it is sometimes useful to add a so-called remanent airgap. This paper explains what we have incorporated into Flux to model this effect due to hysteresis.

All electrical motor designers know that the computation of cogging torque is a tricky task, particularly in 3D. Indeed, the amplitude of this variable is almost the same as numerical noise. In most cases, conventional mesh methodology is not sufficient and specific methodology must be used. At CEDRAT, thanks to its experience, the application team has developed methodologies to successfully computecogging torque in most cases. This article presents a specific mesh methodology to compute cogging torque for 3D non-radial electrical motors.

All electrical motor designers know that the computation of cogging torque is a tricky task in 3D. Indeed, the amplitude of this quantity is almost the same as the numerical noise. In most cases, a classical meshing methodology is not sufficient and specific methodology must be used. At CEDRAT, the application team, thanks to its experience has developed methodologies to successfully compute cogging torque in most of cases. This article presents a specific meshing methodology to compute cogging torque for 2D and 3D radial electrical machine. It begins with some general recommendation concerning the definition of the geometry in order to facilitate the meshing operation. Then, it presents the specific meshing methodology applied to a 2D SPM motor and to a 3D IPM motor.

The paper presents a comparative study of 3-phase permanent-magnet (PM) synchronous machines (PMSM) with concentrated and distributed windings. The purpose of this study is to identify the machine that gives the better electromagnetic performance (torque, efficiency, back electromotive force…). Two PMSM with concentrated and distributed windings having identical output power, stator and rotor outer diameter, airgap, axial length, are designed. Machine performance of the two machines is compared using finite element analysis (Flux 2D).

In the present energy efficiency context of electrical machines, diagnosis of rotating machines is increasingly studied. Designers seek to include the on-line, non-invasive diagnosis and typical signatures of the rotating machines faults in the stator winding currents, torque, leakage magnetic field…etc. Among the rotating machine’s faults, 7 to 10% are located in the rotor and some of these faults are eccentricities. These faults generate electromagnetic torque oscillations: electromagnetic forces acting on the stator, particularly the stator winding, which can accelerate wear of its insulation. Friction between the stator and the rotor is not excluded; this can also have an adverse effect on the bearing.In the literature we often find three types of eccentricities: static, dynamic and mixed. Our Flux 2D/3D/Skew finite element solution can be of considerable help to predict the typical signatures of eccentricities faults and the influence of these defects on the electromagnetic and vibro-acousticperformances of these machines, a very differentiating feature of the software. The purpose of this article is to show the feasibility of the different eccentricities with Flux 2D/3D/Skew thanks to thepossibilities offered by mechanical sets.

In the literature we can find two approaches to make diagnosis: Model approach - a specific method for automation engineers. Depending on the mechanism adopted, we can distinguish three branches in this method: monitoring by observers, by analytical redundancy and by parametric estimation. Signal approach - this approach is based on measurable signals data, such as current, torque, stray flux, noise and vibration, temperature. The principle of this method is to look for frequencies unique to the healthy or fault operation. Faults in electricalrotating machines can induce other phenomena such as noise and vibrations and possibly other faults like friction between the stator and the rotor or accelerated wear of insulations.

The thermal analysis of electrical machines and the related fluid dynamic computation, tasks associated with mechanical engineering disciplines, seem to interest electrical engineers less than electromagnetic analysis. But, with increasing requirements to fully exploit new designs and materials, it has more or less become compulsory to analyze the thermal behavior of electrical machines, to the same degree as electromagnetic design.

Contactless energy transfer (CET) systems are used in many industrial sectors. These include conveyors, trolleys, storage and retrieval units, baggage handling, battery charging stations, mobile phones and medical implants. The energy transfer model is quite similar to a conventional transformer, except for the weak coupling between the primary and secondary windings and partial or non-existent ferromagnetic closing paths. Inductive coupling is commonly used in a range from a few mW to a few hundred kW.

Nowadays Power Transformers need to optimize their efficiency to make sure a minimum amount of losses are generated from the various physical phenomena. Flux Finite Element studies allow transformer designers to accurately analyze the different losses (Joule losses, iron losses, stray losses) to enhance the performance of their transformers. A few steady-state and transient tests permit determining the electrical and mechanical constraints that the power transformer will have to endure in its life. In addition, thermal studies can complete these analyses to detect and prevent hot spots on the tank or in the windings.

Principle of induction heating and forced cooling (shower): induction heating is the process of heating an electrically conducting object without contact. The flowing of the current through the coil (see Fig.1) generates an alternating magnetic field. This field induces current in the electric conductor (eddy current). The repartition of eddy current depends on the shape of the electric conductor, the frequency, and physical properties of the material used in the electricconductor. In addition to this, the high frequency used in induction heating applications gives rise to a phenomenon called skin effect: all the current is concentrated only on the boundaries.

For Switched Reluctance Motor, a specific command of current is often used with a chopper in order to decrease the currentripple or hysteresis band. We propose to see in this example (see Figure 1) how to implement such a command in Flux usinggroovy language.

Requirements: rotating electrical machine designers want high-reliability, minimum power losses, maximum power, maximum torque and low mechanical resonance vibration and noise. To meet the needs of electrical machine designers, CEDRAT started developing tools that take Skew into account in 2003. Several improvements have been made to this tool. Skew is usually accounted for by sub-dividing the active length of the machine into several 2D slices. In the latest Skew version of Flux the post processing is directly a full 3D post-processing.

Materials can be classified according to their magnetic property into two main categories:Soft magnetic materials: which exhibit magnetic properties with the presence of external excitation. Hard magnetic materials: exhibit magnetic properties in the absence of magnetic excitation. Permanent magnets are part of this family.

The article presents the main results of magnetostatic 3D simulation using CEDRAT Flux software especially for new TMR angle sensor applications. Such magnetic sensors are deployed today in automotive electronics, as well as in many new industrial, consumer-product, medical, avionics, defence and other applications. Under Flux 3D, several effects of the influence of magnet geometry parameters and mechanical tolerances of sensor positioning were investigated, such as airgaps and tilts effects. The results include optimum solutions useful for TMR, as well as for a wide range of other angle sensor types and applications.

Nowadays, it is more and more difficult to design electrotechnique devices without considering thermal stress. In more and more applications (electric vehicles, electric aircraft, etc.) there is a need to reduce weight and cost, increase efficiency, whilst maintaining security. One possibility is to increase current for the same device, and therefore how to draw away the heat. This is why conventional approximationsneed to be cross-checked with new tools. These new tools have to be quick and precise in order to run parametric and even optimisation analyses. Of course, thermal analysis is already available in the Flux suite for induction heating, induction hardening, forging, etc. Dedicated applications have been created to couple magnetic AC steady state to thermal transient analysis, for instance. What is new is easierand more effective coupling any type of magnetic application to thermal analysis. This article reviews what thermal analysis is, when the different tools were created, and looks at the latest advances in thermal analysis.

Speeding up Altair OptiStruct* Simulations with the Intel® SSD Data Center Family for PCIe*

Altair OptiStruct* provides engineers and designers with a unified solution from concept to final design by leveraging advanced analysis capabilities and novel, optimization-driven simulation. In this process, the simulation time for one optimization iteration is a critical consideration, since it affects the computational speed and scalability of the entire design process.

Less Interior Squeak and Rattle Noise Using a Simulation Driven Design Approach

In the development of new vehicles, the PSA Group aimed to detect Squeak and Rattle (S&R) problems before availability of physical testing. This led to a collaboration between PSA’s method development engineering team and Altair’s domain experts.

Internet of Things (IoT) is starting to mature and organisations across many sectors are facing the challenges of scaling up from small, trial deployments and proof of concepts into mainstream, high volume consumer deployments.

In this paper, presented at the 2016 SAMPE Long Beach Conference, an aircraft door surround model is optimized with respect to the objectives and constraints typical for this type of component using HyperStudy and ESAComp.

The level of noise transmitted to the passengers of a vehicle can drastically impact a passenger’s comfort. Brake noise will give the customer an impression of poor product quality and can thus damage the quality image of the company. Within the automotive industry, the study of mode coupling instability by the use of FEM and modal complex analysis is widespread to reduce this phenomenon.

The objective of this paper is to assess several optimization algorithms in HyperStudy for their effectiveness and efficiency. The following sections of this paper present an overview of the optimization algorithms frequently used in HyperStudy. This is followed by benchmarking of both single objective and multi-objective optimization problems, respectively.

Printed reflectarrays combine the advantages of parabolic reflector antennas with microstrip arrays, yielding high-gain, low-profile, low-cost antennas with simpler feeds that are easy to fabricate. This white paper demonstrates how FEKO can be used to model a printed reflectarray and its feed.

Altair’s computer-aided engineering (CAE) simulation software platform for simulation-driven innovation is Hyper- Works, which includes modeling, visualization, analysis and optimization technologies and solutions for structural, impact, electromagnetics, thermal, fluid, systems and manufacturing applications. The electromagnetics solver suite in HyperWorks is FEKO, a comprehensive electromagnetic analysis software used to solve a broad range of electromagnetic problems. It includes a set of hybridized solvers, giving the possibility to combine methods to solve complex and electrically large problems, with all solvers included in the same package.

Technology advancement in the electronic industry is unyielding, but new trends will build on RF communications to drive new product functionality. Some examples include the Internet of Things (IoT), 5G mobile networks and automation/smart technology.

The benefit of design exploration and optimization is understood and accepted by engineers but the required intensive computational resources have been a challenge for their adoption into the design process. The HyperWorks Unlimited (HWUL) appliance provides an effective solution to these challenges as it seamlessly connects all the necessary tools together in the cloud. The aim of this study is to showcase the benefits of HWUL on an optimization driven design of a complex system. For this purpose an automotive seat design forcrash loadcases is selected.

This paper discusses the behavior of a flexible flap at the rear end of a generic car model underaerodynamic loads. A strong bidirectional coupling between the flap’s deflection and the flowfield exists which requires this system to be simulated in a coupled fluid-structure manner.

In this work, the multi-disciplinary problem arising from fluid sloshing within a partially filledtanker truck undergoing lateral acceleration is investigated through the use of multiphysicscoupling between a computational fluid dynamics (CFD) solver and a multi-body dynamics(MBD) solver. This application represents a challenging test case for simulation technologywithin the design of commercial vehicles and is intended to demonstrate a novel approachin the field of computer aided engineering.

Optimize every stage of product development with an integrated workflow that democratizes simulation and analysis. In this Desktop Engineering sponsored report Altair's vision for product optimization is analyzed

Turbine blades have internal passages that provide cooling during operation in a hightemperature engine. The design of the cooling passages is critical to achieve near uniformtemperature of the blade during operation. The temperature of the blade is dependent on the thermal properties of the blade material as well as the fluid dynamics of the air circulating in the cooling passages. Computational optimization methods have successfully been applied to design lighter and more efficient structures for many aerospace structures. An extension of these techniques is now applied to guiding the thermal design of a turbine blade by designing the optimal cooling passage layout. Optimization methods will be applied to determine the optimum pattern of the cooling passages and then to optimize the size of the individual cooling passages. The goal is to produce a more thermally efficient turbine blade design that will produce blades with longer lives and better performance.

With Cray and Altair, engineers have the computational systems they need to perform advanced subsea computational fluid dynamics (CFD) analysis with better speed, scalability and accuracy. With Altair’s AcuSolve CFD solver running on Cray® XC30™ supercomputer systems, operators and engineers responsible for riser system design and analysis can increase component life, reduce uncertainty and improve the overall safety of their ultra-deep-water systems while still meeting their demanding development schedule.

Distortion induced in parts due to the cooling of welds complicates automated manufacturing lines in the automotive industry. The resulting deformation leads to additional investment such as end of line machining to correct affected assemblies. Utilising optimisation software a welding pattern can be found which retains the intended performance of a part while reducing the distortion induced from welding. Weld locations may be optimised alongside welding sequence to allow process requirements to be considered within the early design stage. This leads to high performance, low distortion assemblies which can ultimately be manufactured at the lowest possible cost.

As design exploration and optimization methods have become commonly accepted across a range of industries, such as aerospace, automotive or oil and gas, they are frequently utilized as standard practice to efficiently produce designs and aid critical engineering decisions. This paper present an overview of the practical usage of Altair HyperStudy's GRSM optimization algorithm, followed by application problems of railcrush design optimization for a single and multi-objective formulation.

External aerodynamic simulations using computational fluid dynamics (CFD) are well established tools in the product development process forthe automotive and aerospace industries. CFD simulation technology helps engineers to understand the physical phenomena taking place intheir design and provides an environment to optimize the performance with respect to certain design criteria.

This paper examines practical uses of the PBS Professional® hook mechanism, to help achieve site requirements, based on experiences at The University of Queensland Research Computing Centre. The paper includes descriptions of several real-world applications for job submission hooks (qsub_hook) and includes example code to help commence implementation of a generic hook able to handle both job submission and job modification events.

The Schlumberger ECLIPSE software family offers the industry’s most complete and robust set of reservoir simulation software. In response to user requests, Altair has collaborated with Schlumberger to deliver a tightly integrated version of ECLIPSE for PBS Professional. This paper documents the integration and provides step-by-step instructions for configuration and use.

One of the most difficult jobs of a NVH Analyst is to sift through a seemingly endless set of results and find the key conclusions that will improve a design. Different assumptions and different subsets of data can give very different conclusions. This paper compares acoustic results calculated for a Class 8 heavy duty truck cab to choose an optimal configuration of damping material. The design was evaluated for structure and air-borne inputs, but only structure-borne inputs are considered in this paper.

Usage of fiber reinforced composite material entered an new era when leading aircraft OEMs took an unprecedented step to design and manufacture essentially full composite airframe for commercial airliners. Composite structures offer unmatched design potential as the laminate material properties can be tailored almost continuously throughout the structure. However, this increased design freedom also brings new challenges for the design process and software. Moreover, as a relatively new material, composite behaviors are more complex and less fully understood by design engineers. Therefore, reliable simulation for highly complex events like bird strike and ditching can play an important role in shortening the product design cycle. This paper showcases two area of CAE tools for composite applications. On advanced simulation, bird strike simulation with Altair RADIOSS [1] is demonstrated on an aircraft underbelly fairing. On design optimization, an airplane wing structure is designed using an innovative composite optimization process implemented in Altair OptiStruct [1-3]. OptiStruct has seen increasing adoption among aerospace OEMs, as demonstrated in the Bombardier application process described in this paper.

Working closely with Intel, Altair has ensured that PBS Professional supports the Intel® Xeon Phi™ architecture targeting high performance computing applications. This paper describes the basic and advanced configurations of PBS Professional for scheduling jobs onto Intel Xeon Phi devices.

PBS Professional Utilizes Intel Cluster Checker to Validate the Health of an HPC Cluster

On clusters that are Intel® Cluster Ready (ICR) certified, PBS Professional can utilize Intel® Cluster Checker for gathering real-time information about the cluster at the very moment a job has been scheduled. Using this immediate feedback, PBS Professional can ensure that a job is only being executed on a cluster that has passed a check by Intel Cluster Checker.

A methodology is presented to apply CFD to study air flow around a rotating bicycle wheel in contact with the ground. The bicycle wheel studied here is an accurate geometrical representation of a commercial racing wheel (Zipp 404). Reynolds-Averaged Navier Stokes (RANS) and Delayed Detached Eddy Simulation (DDES) results are computed at a range of speeds and yaw angles commonly encountered by cyclists. Drag and side (or lift) forces are resolved and compare favorably to experimental results obtained from wind tunnel tests. Vertical forces acting on a rotating bicycle wheel are presented for the first time. A unique transition from downward to upward acting force is observed as the yaw angle is increased. Flow structures are identified and compared for different yaw angles. It is expected that a more complete comprehension of these results will lead to improvements in the performance and handling characteristics of bicycle racing wheels used by professional cyclists and triathletes.

A Comparative Aerodynamic Study of Commercial Bicycle Wheels Using CFD

A CFD methodology is used to study the performance of several commercial bicycle wheels over a range of speeds and yaw angles. The wheels studied in this work include the Rolf Sestriere, HED H3 TriSpoke, the Zipp 404, 808 and 1080 deep rim wheels and the Zipp Sub9 disc wheel. Wheels are modeled at speeds of 20mph and 30mph, in contact with the ground, using Reynolds-Averaged Navier Stokes (RANS). Drag, vertical and side (or lift) forces are reported for each wheel. Turning moments are also calculated using the resolved sideforces to examine aspects of stability and maneuverability. Drag and side forces over the range of yaw angles studied compare favorably toexperimental wind tunnel results. The previously reported unique transition from downward to upward acting vertical force on the Zipp 404 wheel for increasing yaw angles is observed for all deep rim wheels and the disc wheel studied here. Wheels were also modeled at a critical yaw angle of 10 degrees using Delayed Detached Eddy Simulation (DDES) to examine the transient aspects of flows around moving bicycle wheels. It is hoped that a more complete comprehension of these results will lead to improvements in performance, safety and control of bicycle racing wheels used by amateur and professional cyclists and triathletes.

A Practical Analysis of Unsteady Flow Around a Bicycle Wheel, Fork and Partial Frame Using CFD

CFD is used to study air flow around a rotating bicycle wheel in contact with the ground, extending previous ‘wheel-only’ work on this problem by including the fork, head tube, top tube, down tube, caliper and brake pads. Unsteady simulations, using a Delayed Detached Eddy Simulation (DDES) turbulence model, were run for 9 different wheel and front fork configurations, over 10 different operating conditions (5 yaw angles, repeated for two different speeds, commonly encountered by cyclists), resulting in 90 transient design points.

Several operational numerical weather prediction (NWP) centers will approach a petaflop of peak performance by early 2012 presenting several system operation challenges. An evolution in system utilization strategies along with advanced scheduling technologies are needed to exploit these breakthroughs in computational speed while improving the Quality of Service (QoS) and system utilization rates. The Cray XE6™ supercomputer in conjunction with Altair PBS Professional® provides a rich scheduling environment designed to support and maximize the specific features of the Cray architecture.

An Integrated Approach to Workload and Cluster Management: The HP CMU PBS Professional Connector

This paper describes the integration between Altair’s PBS Professional and HP’s Insight Cluster Management Utility (CMU), explaining how the concept of a “connector “unites these two tools to simplify cluster setup and job execution, and providing instructions for performing key PBS Professional tasks within Insight CMU. Click here to access more CMU resources.

With the advent of the Graphical Processing Unit (GPU) as a general-purpose computing unit, more and more customers are moving towards GPU-based clusters to run their scientific and engineering applications. This model allows users to use a CPU and GPU together in a heterogeneous computing model, where the sequential part of the application runs on the CPU and the computationally-intensive part runs on the GPU.

Composite structures offer unmatched design potential as laminate material properties can be tailored almost continuously throughout the structure. Moreover, composite laminate can be manufactured to fit the ideal shape of a structure for aerodynamic and other performances. However, this increased design freedom also brings new challenges for the design process and software. It is shown in this paper that optimization technology is well suited to exploit the potentials that composite materials offer.

TECOSIM has developed techniques which can shorten the folding & packaging process time to a few hours and still achieve the essential airbag deployment performance. We will present methods which rapidly fold a free mesh and allow for rapid shape changes for a detailed folded model. These methods can significantly reduce the turnaround time to incorporate design changes into the working CAE model for side impact and OOP [Out Of Position] studies. This technology can integrate airbag development further into the virtual world to allow ‘CAE led’ design of airbag profiles, chambers and seam lines to be established early in the design phase and establish a fully folded deployable airbag for all virtual phases.

The Use of MBD Modelling Techniques in the Design and Development of a Suspension System

This paper describes the use of Multi-body Dynamics (MBD) modelling techniques in the design and development of a suspension system for a novel autonomous vehicle. The general approach and philosophy is described, whereby MBD techniques are used in conjunction with an independent (parametric) whole vehicle handling simulation. This is supplemented with examples, showing how MotionSolve was used (in tandem with CarSim) to develop the suspension elasto-kinematic geometric properties to meet specific cascaded targets, to optimise a weighing strategy, to predict forces under a variety of quasi-static and dynamic loads, and to estimate response to track inputs.

As the UK Ministry of Defence (MoD) Design Authority for Aircraft Arrestor Barrier Nets, AmSafe products are used to stop aircraft from over-running the end of the runway. The British Arrestor Net (BAN) Mk2 is suspended across the runway over-run area by two electrically driven stanchions and raised or lowered by remote control from the Air Traffic Control tower.

This paper describes the process and results of a FE analysis of the engagement of the Hawk T Mk2 aircraft into a Type A Barrier (BAN Mk2). The analysis was performed using RADIOSS, an advanced non-linear explicit Finite Element solver.

Biomechanics modelling is becoming increasingly accepted as a tool for enhance assessment of vehicle safety, in particular in the field of injury assessment and virtual testing. Firstly, a generic RADIOSS model for safety applications (HUMOS2) is presented and applications are demonstrated. Important tools associated with the scaling, and positioning of the model is also described. Secondly, an innovative model for scaling of human organs (individualization) is presented. The method which employs optimization techniques, identifies critical (optimal) anatomical control points which allow for a best scaled model of the HUMOS2 representing an individual. Finally, some remaining challenges for future human models are discussed and solution paths are described.

Automotive Modal Testing Support and CAE Correlation Using Altair HyperWorks

To derive the natural frequencies and mode shapes of a given structure, the test Engineer has to decide on excitation positions that will efficiently excite all the modes of the structure in the frequency range of interest. Excitation positions are usually decided upon from experience or trial and error methods which can be time consuming and still not capture all of the modes in the selected frequency range. Using Altair HyperStudy and Radioss (bulk), Pre-test CAE analysis has been carried out to identify effective excitation positions before the commencement of modal testing, thereby significantly reducing pre-test lab time.

The Application of Process Automation and Optimisation in the Rapid Development of New Passenger Vehicles at SAIC Motor

As a relatively young automotive company, SAIC Motor has drawn on the expertise of its UK Technical Centre to help in its objective to bring a new range of vehicles to market in an aggressive time frame. CAE has formed an integral part in doing this and the UK technical centre has worked closely with Altair Product Design amongst others to utilise its Engineers’ skills as well as the Hyperworks suite of software.

The paper aims to showcase what has been achieved to date, on the Roewe 550 medium car programme - currently on sale in China - and on another current vehicle programme, where processes have been developed further. Several interesting optimisation examples are highlighted in the development of the body structure as well as some key process improvement methodologies which have been jointly developed between SAIC and Altair to streamline the design process.

Packaging designers must constantly inject innovations to attract consumers in a constantly evolving and highly competitive market. Keeping ahead of the competition by bringing new and exciting products to market faster whilst maintaining quality, presents a major engineering challenge. A new packaging development process is described, which introduces advanced automated simulation and optimization technology right from the concept development phase. Detailed predictions of primary, secondary and tertiary packaging performance are made possible through use of advanced simulation technology. Design optimization is then employed using the modelling as a virtual testing ground for design variants. The approach provides clear design direction, an opportunity for wider experimentation, helps to improve performance and reduces uncertainty in the development process.

This paper details the use of the Thyssenkrupp eDICT process for the design of sheet metal chassis components. eDICT (evolutionary design in chassis technology) is an innovative structured process flow for the design of optimal structures. eDICT uses the optimisation capability of Optistruct with a set of custom tools to guide and translate a design into a production feasible sheet metal solution. Fundamentally it reverses the usual design loop of CAD first then CAE assessment. The function is used to determine the design and the form follows. On recent projects eDICT has produced 25% mass reductions compared to the current series design. eDICT is also able to reduce development times and resource with an efficient solution production right from the outset.

Bombardier Transportation UK offers one of the most comprehensive and diverse rail vehicle portfolios in the world. The strategy is one of continuous development that provides the most effective and cost-efficient rail solutions for today and the future. A key ingredient is the use of Altair HyperWorks enterprise computer aided engineering (CAE) solution. Altair's technology is now present at every stage of the design process and has increased the efficiency of the product development process. The paper details how Altair tools have been used to generate Finite Element (FE) models of carbodies, bogies and secondary structures in reduced time scales. Significant weight and cost savings are achieved through structural optimisation of components such as large steel castings, aluminium extrusions and steel fabricated structures which are subjected to linear static, fatigue and abuse loading. Automated post processing facilitates the interpretation of results and the writing of detailed official reports.

This paper shows how Altair OptiStruct, part of the HyperWorks suite, is used to provide a complete solution when designing with laminated composites, taking the design through concept stages to producing the final ply lay-up sequence. The technology is applied to the design of a laminated wing cover to produce a mass optimised design which meets the requested structural targets.

This paper will show the application of a 3-stage approach to designing the optimum composite structure for a front wing on a Formula One car using Altair OptiStruct 9.0 Continual development of aerodynamic components is normal practice in the world of Formula One and the time taken to respond is paramount if a team is to be competitive.

FACTOR 001 is the result of a creative project by BERU f1systems to explore the transfer of design approaches, technology and materials from Formula One to a groundbreaking training bicycle. The design brief did not require the bicycle to comply with existing technical regulations, which resulted in great freedom during the design process. This paper details how OptiStruct Optimisation tools were used to help generate efficient lightweight solutions for the design of complex carbon fibre components. Free-size optimisation was used to generate laminate boundaries, ply thicknesses and fibre directions, which met stress and displacement requirements. Physical testing carried out on manufactured parts highlighted the accuracy of the FE models and demonstrated the advantages of incorporating OptiStruct Optimisation tools in the design process.

The new Fiesta is about premium feel of a larger car, delivers a new level of safety, driving quality and efficiency. The new Fiesta will be a great contribution towards sustainability and cost effective motoring. The first thing to notice is the design, but the vehicle performance and body structure attribute behaviour are the specific highlights to point out in this presentation. The attribute performance is not based on coincidences; the performance is a result of state of the art engineering work. Especially the safety performance in EuroNCAP.

Multi-Disciplinary Design of an Aircraft Landing Gear with Altair HyperWorks

NAFEMS invited several software vendors to a roundtable in 2007 to demonstrate their best processes in the design of arealistic aircraft landing gear system. (Figure 1). The emphasis was on simulation processes that can make problem solving innovative, accurate and efficient. This paper explains theprocesses followed by engineers at Altair and should help increase awareness regarding the powerful tools available for solving realistic design problems.

A New Approach to Optimizing the Clean Side Air Duct Using CFD Techniques

An integrated approach to CFD design optimization is proposed. It consists of taking an initial CAD design, meshing it using HyperMesh, analysing it using Star-CD, parameterising its key features using HyperMorph, and then shape optimizing it using HyperStudy. This approach has been applied here to the shape optimization of the compressor inlet duct of a turbo system.

This paper details the extensive use of CAE optimisation technology at ThyssenKrupp Automotive Tallent Chassis Ltd (TKA). There are a number of trends in the automotive business that are presenting great challenges, these include severe cost pressures from OEM’s, platform commonisation and reduced vehicle development cycle time. The use of optimisation is critical for TKA to maintain its competitiveness, this paper deals with more advanced concepts of optimisation by extending into the severely non-linear region of analysis types.

A Holistic Virtual Design Process Applied to the Development of an Innovative Child Seat Concept

There is a need to minimise product development costs and provide efficient design solutions to maintain competitiveness, so increasingly companies in the Child Restraint System (CRS) industry are turning to Computer Aided Engineering (CAE) to enhance the design and development for their products. Graco has worked with Altair Engineering to develop a group 1 CRS using an advanced CAE driven design process. The design process introduces a number of key phases in the design cycle each of which are positioned to maximize the efficiency of the structure and reduce or remove the cost involved in a traditional, iterative ‘test it and see’ approach.

The use of CAE software tools as part of the design process for mechanical systems in the automotive industry is now commonplace. This paper highlights the use of Altair HyperWorks to assess and then optimize the performance of a McLaren Automotive front suspension system. The tools MotionView and MotionSolve are used to build the model and then carry out initial assessments of kinematics and compliance characteristics. Altair HyperStudy is then used to optimize the position of the geometric hard points and compliant bush rates in order to meet desired suspension targets. The application of this technology to front suspension design enables McLaren Automotive to dramatically reduce development time.

Millimeter wave (mmWave) antennas operate in the band of frequencies where the wavelength is between 10mm and 1mm. The frequencyrange for mmWave application is thus constrained to be greater than 30 GHz, but less than 300 GHz. Various applications exist inthis frequency range, including wide band telecommunication and imaging applications for security screening. This white paperdemonstrates how an antenna was designed for communication at 60 GHz.

FEKO offers a wide spectrum of numerical methods and hybridizations, each suitable to a specific range of applications. Hybridization of numerical methods allows large and complex EM problems to be solved.

This white paper demonstrates how resource requirements scale for the computational electromagnetic modeling of a modern fighter aircraft when the frequency increases. It also demonstrates how different simulation methods may be applied and how they scal relative to each other